Electrode control system



Dec. 2, 1941. c. c. LEVY 2,264,704 ELECTRODE CONTROL SYSTEM Filed Jan. 5, 1940 WITNESSES: INVENTOR I Quf Patented Dec. 2, 1941 ELECTRODE CONTROL SYSTEIVI Cyril C. Levy, Pittsburgh, Pa., assignor to Westinghouse Electric & Manufacturing Company, East Pittsburgh, Pa., a corporation of Pennsylvania Application January 5, 1940, Serial No. 312,534

8 Claims.

My invention relates, generally, to control systems, and it has reference, in particular, to movable electrode control systems.

It is an object of my invention, generally stated, to provide in a simple and effective manner for controlling the movement of a movable electrode so as to maintain predetermined arc conditions.

More specifically, it is an object of my invention to control the movement of an electrode in accordance with current and voltage conditions of an arc produced by the electrode, and provide for reversing the direction of movement of the electrode in accordance with predetermined current conditions in the electrode circuit.

Another object of my invention is to provide for normally feeding a movable electrode at a predetermined rate and selectively increasing or decreasing the rate of feed in accordance with conditions in the electrode circuit.

A further object of the invention is to provide an electrode control system which is sensitive to slight changes in the arc conditions.

Yet another object of my invention is to provide a simple and inexpensive control for a movable electrode which may be readily and economically manufactured and maintained.

Other objects will, in part, be obvious, and will, in part, appear hereinafter.

In practicing my invention, a movable electrode for maintaining an arc in an electric furnace, a welding process, or other similar operation, may be provided with reversible actuating means of any suitable nature, and may be connected to a source of energy by a suitable electrode circuit. The operation of the actuating means may be controlled by regulating means responsive both to current and voltage conditions of the electrode circuit, so as to vary the rate of feed of the electrode in accordance with variations in the conditions of an are produced by the electrode. The direction of electrode feed may be controlled so as to normally provide for feeding the electrode under the control of the regulating means in one direction, and reverse the direction of electrode feed when the current in the. electrode circuit exceeds a predetermined value. Manual control means may also be provided for controlling the operation of the actuating means under the operators control when desired, so as to vary both the rate and direction of electrode feed.

For a more complete understanding of the nature and scope of my invention, reference may be single figure of the drawing, which illustrates diagrammatically a movable electrode system embodying the principal features of my invention.

Referring particularly to the drawing, the reference numeral it! may denote a movable electrode which is to be actuated so as to strike and maintain an are for any desired purpose, such as, for example, in connection with the work 12 which may comprise a material to be melted in the cupola :4 of an electric furnace.

Electrical energy may be supplied from any suitable source by means of an electrode circuit which includes a transformer 26, the terminals of which may be connected to the electrode l3 and the work l2 through the cupola M, by the conductors 2| and 22, respectively.

In order to provide for feeding the electrode 53 to produce and maintain an arc with the work suitable actuating or feeding means comprising a motor 24 having an armature 26, a series field winding 2'! and a shunt field winding 23, may be utilized, the armature 26 being connected in driving relation to the feed rolls 29. Suitable means such as the limit switches 30 and 32, disposed to be actuated upon predetermined movement of the electrode It, may be provided in connection with the electrode feeding means for controlling the operation of the feed motor 24 to prevent over-travel of the electrode at either the upper or lower end of a feeding operation.

In order to control the direction of electrode feed, suitable means such as the switches 36 and 38 may be provided for connecting the armature 26 to the supply conductors 40 and 42, so as to control the direction of current flow therethrough.

In order to reduce the current drawn by the motor 24 at the moment of starting, a current limiting resistance 43 may be connected in series circuit relation with the armature 25. A suitable time delay relay 44, of any well-known type, having a damper winding about the armature, may be provided for cutting the resistance 43 out of the armature circuit a predetermined time after starting. For example, the relay 44 may be provided with normally closed contact members 44a connected to provide a shunt circuit about the resistance 43, and an operating winding 45 which may be energized to effect immediate operation of the relay to insert the resistance 43 into the armature circuit. A predetermined interval after deenergization of the winding 45, the relay returns to the deenergized position and again shunts the resistance 43 out of the armahad to the following detailed description and the 55 ture circuit.

The field winding 28 of the motor may be provided with a suitable current controlling rheostat 46 for manually controlling the field current so as to permit the operator to vary the speed of the motor as desired. With a view to automatically controlling the speed of the motor 24, suitable means may be provided for automatically varying the field current of the motor. For example, an adjustable current limiting resistance 4'! may be connected in series circuit relation with the field winding 28 of the motor, and suitable means, such as the field switch 48, provided tor shunting a portion of the resistance in order to increase the field current and reduce the motor speed. In addition, suitable means such as the adjustable resistance 50 may be providedhavi-ng a field switch 52 for connecting it in shunt circuit relation with the field winding 8 so as to reduce the field current and increase the motor speed from a predetermined normal value.

In order to manually control the operation of the reed motor 24, manually operated control switches 54 and 56 may be provided for controlling the energization of the operating windings 53 and of the field switches 48 and 52, respectively. Manually operable forward and reverse switches 82 and 64 may be provided for controlling the energization of the operating windings 66 and 68 of the armature swit ches' 3' and 38, respectively, in a similar manner, so as to provide for manually controlling the "direction of operation of the feed motor 24. Suitable means, such as, for example, the master control switch may be provided for connecting the control bus 1 I, from which the manually operated switches are energized, to the supply conductor 42 when it is desired to manually control the operation of the feed motor. 2

In order to control the operation of the feed motor 24 in accordance with the conditions ir the electrode circuit so as to provide a sensitive and efiicient electrode controlsystem, sui ble means such as, for example, the regulator 12 may be provided for controlling the operation oi the field switches 48 and 52 so as to vary the speed ef the feed motor 24 in accordance with the'current and voltage conditions of the electrode circuit. For example, the regulator 12 may comprise a movable contact arm 14 pivotally mounted intermediate the armatures' It and I8 ior actuating relatively movable contact members 12g. and l2 b. Operating indingsBD and 82 may be provided for actuating the'armatures l6 and '18, respectively.

The operating winding 80 may be energized in accordance with voltage'conditions of the are by being connected across the conductors 2i and 22 which connect the electrode IO and the cupola l4 in which the work I2 is positioned to the source of current. The operating winding 82 may be energized in accordance with current conditions in the electrode circuit'byconnecting it to the terminals of a current transformer as, the primary winding of which is connected in series circuit relation in the electrode circuit. Suitable means may be provided for varying the realtive energization of the voltage and current windings 8!! and 82 of the regulator 12 in order to adjust it to maintainpredetermined arc condi: tions. For the purpose of adjusting the relative energization of the current and voltage windings, an adjustable resistor 88 may be connected so as to vary the current throughthe current wind: ing 82. By suitably connecting the regulator 12 to control the energization of the operating wind:

ill

ings 58 and 60 of the field switches 48 and 52, the speed of the feed motor 24 may be varied in accordance with changes in the current and voltage conditions of the electrode circuit.

In order to provide for automatically reversing the direction of feed of the electrode 10, suitable means such as, for example, the current responsive relay 89 may be provided. The operating winding 99 of the relay 89 may be connected in series circuit relation with the current winding 82 of the regulator 12 so as to be energiaed in accordance with the current in the electrode circuit. By suitably connecting the contact members 390, {19c and 89d of the current responsive relay9 in the energizing circuits of the operating windings 66 and 68 of the armature switches 36 and 38, respectively, the direction of operation of the feed motor 24 may be controlled so as to reverse the direction of electrode feed when the current in the electrode circuit exceeds a predetermined value.

By providing the current responsive relay 55 with additional contact members 836 and 394', the energization of the operating widings 5,8 and 60 9 t e fi w t he 4 and 52, respect ve ma also be ontmllsd s as t e b d e t eor siation of the feed motor 24 at a relatively high speed when the current responsive relay flil 'i's operated in accordance with excessive current in the electrod circuit, so as to' insure a rapid withdrawal of the electrode!!! from the worl; and facilitate the immediate I sired are conditions. 7

Suitable o t mass m be ro i ed er effecting mat s ntrsl oi he ele rode eed. F x m e e l e s q sivs 1 2? 03 trol switch 9| may be provided tor connecting the control us TI o t e sogdustq 4?- A start rushbuttori s ch 92 and a st p nu hbstise switch 93, may e rs idsd is? sent q liu the s s s o @115? rat n Wi li ms .94 Q1 th m sn s w s 9' o senses; and d sconnect the tr l ys sg to and fr m the uppl conductors,

I it s des r d o manua ly c ntrol th eed of th l rode '9. the mas er control switch In. is Operated is slq s c ntes memb r 10a a d 99 n es memb r 91. thu conn ct n h control bus H to the supply conductor 4?. Since he e i n u re t ow n n t e electrod i u t nd onl h vo ta e windin 59 of the rash: aw 1 i ene i ed the c ntact arm oi the re ulato 1 w ll be in uch a s i t h n c memb r 12b: ar c os d, hus. provid n an ener zin cu t for e ope at n wi din {ill of the field swi ch. thro the circuit from he s p l on uctor .2, throu h, ontac mem-v b 1.6 1 the cont ol us 1!. res stor .5, norma ly closed contact members 55a, conductor 95 closed n a t membe s 2b. co ductor 91. operatin windin 6 and nductor 98. to supply can: ductor 40. Operation of the field switch ,60 provides a shunt circuit about the field winding 2.8, t rou h the resistance 50. and conta t m m: bers 52 1, thus weakening the motor field so that when the motor is started it will feed the e1ec= trode toward the work at a relatively high rate of speed.

Upon operation of the master control switch 10, the operating winding 45 of the time delay relay 44 is also energized through the circuit which may be traced from the supply conductor 40 hrou h on uctor 19 Conduc o L02, pera ing windin 4 normall clo ed contact mem: bar 3& and 36s; to the cont l bus 'Ihe ssiab 'i m m t e detime delay relay operates to open normally closed contact members 44a and insert the resistance 43 in the armature circuit and close contact members 44?).

By operating the forward manual control switch 62, an energizing circuit may be provided for the operating winding 66 of the armature switch 36, through the circuit extending from the control bus II, conductor I04, contact members 44b, conductor I05, contact members 62b, contact members 94a, conductor I06, contact members 3219, conductor I08, contact members 890, conductor IIO, operating winding 66, conductor I02, and conductor I09 to the supply conductor 40. The armature 2B of the motor is thereby connected by means of the contact members 36a and 39?) across the supply conductors 40 and 42, and the feed motor 24 operates to feed the electrode I in the direction of the work I2 at a rate determined by the setting of the manually operated field rheostat 50 and the adjustable resistance 41. A holding circuit is provided for the operating winding 69 through contact members 30d.

As soon as the electrode I0 engages the work I2, a relatively large current flows in the electrode circuit so that the current responsive relay 89 operates, deenergizing the operating winding 66 of the armature switch 35 by opening contact members 890. The armature switch 36 returns to the deenergized position and the operating winding 45 of the time delay relay 44 is thereby energized through contact members 380 and 380 so that the relay operates, completing an energizing circuit for the operating winding 68 of the armature switch 38 through the normally open contact members 89d of the current responsive relay 89 and the normally open contact members 44b of the time delay relay. The armature switch 38 operates and the armature 2B is thereby connected across supply conductors 40 and 42 through contact members 38a and 3812 so that the direction of current flow therethrough is reversed and the electrode feed motor 24 thus operates to reverse the direction of electrode feed so that an arc is drawn between the electrode I0 and the work I2.

Subsequent control of the electrode may be effected manually, if desired, by operation of the forward control switch 62 to effect forward feed of the electrode I0 and thereafter controlling the rate of feed by operating the control switches 54 and 56 which control the field switches 48 and 52 to obtain the desired rate of feed, or the operation of the feed motor may I be transferred to automatic control by closing the start pushbutton switch 92 and opening the master control switch 70 to the position shown.

If desired, complete control of the electrode I0 may be effected automatically by operating the master control switch I0 to open contact members a and close contact members 101), as shown, and closing the start pushbutton switch 92. An energizing circuit is thereby provided for the operating winding 94 of the master control relay 9I for operating the relay to connect the control bus II to the supply conductor 42, through the contact members 9Ib. Auxiliary contact members 9Ia may be provided in shunt circuit relation with the start pushbutton switch 92 to provide a holding circuit for the operating winding 94 of the master control relay.

Upon the connection of the control bus II to the supply conductor 42, the field winding 28 of the feed motor 24 is energized. The operating winding 45of the time delay relay 44 is also energized and the relay operates to insert the starting resistance 43 in the armature circuit and close contact members 442). Since there is no current flowing in the electrode circuit at this time, the current responsive relay 89 is in the deenergized position so that an energizing circuit is provided for the operating winding 06 of the armature switch 36, through the circuit extending from the control bus 'II, through conductor I04, contact members 44b, conductor I05, conductor IIB, contact members 102;, conductor I20, contact members 89c, conductor I22, contact members 64a, conductor I06, contact members 322), conductor I08, contact members 890, conductor I10, operating winding 8!, conductor I02, and conductor I00 back to supply conductor 40. The switch 36 operates, thus connecting the armature 2K5 across the supply conductors 40 and 42.

When the electrode circuit is deenergized, the contact arm I4 of the regulator I2 is in such a, position that the contact members 1212 are closed for providing an energizing circuit for the operating winding 60 of the field switch 52, extendingfrom the supply conductor 40 through conductor 98, operating winding 60, conductor 91, contact members 127), conductor 96, contact members 56a, resistor and control bus II to conductor 42. The field switch 52 thus operates to reduce the field current of the feed motor 24 so that the electrode I0 is fed towards the work I2 at a relatiyely high speed.

Upon the engagement of the electrode ID with the work I2, a relatively high current flows in the electrode circuit so that the regulator I2 operates to open contact members 12b and to close contact members 12a. At the same time, however, the current responsive relay 89 operates, interrupting the energizing circuit of the operating winding I56 of the armature switch 36 by opening contact members 890 and providing an energizing circuit for the operating winding 68 of the armature switch 38 in a manner hereinbefore described. The connections of the armature 26 to the supply conductors 40 and 42 are thereby reversed, so that the feed motor 24 reverses to withdraw the electrode I0 from the work I2, thus striking an arc.

By providing the current responsive relay 89 with normally open contact members 89a, connected in shunt circuit relation with the contact members 12?) of the regulator I2, and normally closed contact members 891) connected in series circuit relation with the contact members 120. of the regulator, the field switches 48 and 52 may be operated under the control of the current responsive relay 8:) during reversal of the electrode feed, instead of under the control of the regulator 12.

By connecting the auxiliary contact members 89a and 89b in this manner, the operating winding 60 of the field switch 52 will be energized during the reversal of the electrode feed, and the operating winding 58 of the field switch 48 will be deenergized. Thus, the feed motor 24 will operate at a relatively high speed to withdraw the electrode I0 from the work I2 so as to facilitate rapid establishment of the proper are conditions.

When the arc current is reduced to the predetermined value required for the operation of the current responsive relay 89, the relay returns to the deenergized position, and provides for the energization of the operating winding 66 of the m u i c 3 endtl de siza ion o he operating winding 68 of; the armatureswitchddin a ner nbefqr desc bed e ail, so h h e m is h erate o eed the electrode in the direction ofthe work,

While the electrode It is fed in the direction of the Work [2 the regulator 12: operates to; control the field switches 45 and 52; so; as to vary the speed of the feed motor in accordance with the current and voltage conditions; of the arc. Ii" the arc is longer than a predetermined suitable value, the arc voltage will be greater than normal and the arc current less than normal. The energization of the voltage winding 80; of the regulator is therefore increased, and at thesarne time, the energization of the current winding 82 is decreased. As the changes in thepulls exerted by the two windings effected by the changesin both of these conditions are additive in actuating pivoted contact arm 14, sensitive, operation of the regulator 12 is thereby secured. The contact member "M a is closed, completing an energizing circuit for. the operating winding 6!] of.- the field switch 52 so that the speed of the feed motor 24 is increased, in an efiort to reducethe length of the arc to the desired'value.

lithe length of the arc becomesless than the normal predetermined value, the voltage of the arc decreases, and the arccurren-t increases. The relative energization of the voltage winding 80 and the current winding 82 of the regulator 1-2- is thereby reversed so that the contact arm 14 is actuated in the reverse direction and the contact members 72a are opened and the contact members 1212 are closed. The energizing circuit for the operating winding 60 of the field 52 is thereby interrupted, and an energizing circuit is provided for the operating winding 58 of the field switch 48, so that the speed of the feed motor 24 is decreased, thus permitting the electrode to melt and-lengthen the arc.

When the arc length is of the desired length, the contact members 12 and 1212 are both open and the field switches 48 and are both deenergized. The feed motor 24 :then operates at a predetermined speed determined by the adjustment of the resistance 41 and the manual field rheostat 416 From the above descrip i n a d; h a panying drawing, it will be realized that Ihave, by my invention, provided asimple and effective manner for controlling the rate of feed and the direction of feed of; a movable electrode for an arc furnace, a welding operation, or other similar application. By controlling the rate of feed in accordance with both, the current and voltage conditions of the electrode circuit in the manner hereinbefore described, sensitive and accurate control of the arc length is obtained. By providing for controlling the direction of electrode feed in accordance with predetermined. current conditions, rapid establishment of the arc is easily secured. Operation of the actuatingmeans may be readily transferred from manual tqaullomatic control at the will of theoperator, thus providing a complete and practical control system which is simple and flexible to operate and inexpensive to maintain.

Since certain changes may be made in the above description, and different embodiments of the invention may be made without departing from the spirit thereof, itisintendedthat all the matter contained in the above description or hQ n' n the a c mpa y ng drawin shall be considered as illustrative, and not; in a limiting sense.

I claim as my invention: 1. The combination with an electrode circuit having a movable electrode with a reversible variable speed feed motor operatively connected therewith for feeding the electrode, of control means for selectively increasing or decreasing the speed of the feed motor from a predetermined normal value, regulating means having current render the regulating means inoperative.

2. A control system for electrode actuating means adapted to feed a movable electrode at varying rates and in opposite directions for striking and maintaining an arc comprising, control means responsive to predetermined arc current and voltage conditions, manually operable switch means, electro-responsive switch means operable under the control of the control means or the switch means to determine the rate of operation of the electrode actuating means, and means responsive to current conditions of the are for controlling the direction of operation of the elec trode actuating means,

3. The combination with an electrode circuit having a movable electrode with a reversible feed motor capable of varying speed operatively connected thereto for feeding the electrode, of switch means operable to increase the speed of the motor above a predetermined value, additional switch means operable to decrease the speed of the motor below the predetermined value, and control means differentially responsive to current and voltage conditions in the electrode circuit for controlling the operation of the said switch means to vary the rate of electrode feed from the predetermined normal in one direction to maintain predetermined. current and voltage conditions in the circuit, and relay means controlling the feed motor and the switch means operable to reverse the direction of electrode feed when the current exceeds a predetermined value.

4. A control system for a movable electrode adapted to maintain an. electric arc and having a reversible variable speed feed motor operatively connected thereto, of manually operable switch means, control means having a current winding energized in accordance with the arc current and an opposing voltage winding energizedin accordance with the arc voltage, electro-responsive means controlling the speed of the feed motor to increase or decrease it from a predetermined normal speed, and control switch means for selectively placing the electro-responsive means under the control of the manual switch means or the control means.

5. The combination with a movable electrode adapted to maintain an arc, of a reversible variable speed motor operatively connected to feed the electrode at a predetermined normal rate in said one direction, regulating means responsive to current and voltage conditions of the arc to vary the speed of the feed motor to feed the electrode at a different rate in said one direction, and means responsive to predetermined arc current conditions, for controlling the feed motor to reverse the direction of electrode feed and increase the rate above the normal.

6. An electrode feeding system comprising, a movable electrode, an electrode circuit for connecting the electrode to a source of current, reversible variable speed actuating means for feeding the electrode to produce and maintain an arc in the electrode circuit, control means responsive to current and voltage conditions of the electrode circuit for controlling the actuating means to vary the rate of feed of the electrode, and means responsive to predetermined current conditions for controlling the actuating means to reverse the direction of electrode feed and rendering the control means inoperative.

7. A control system for a movable electrode adapted to produce an arc in an electrode circuit and having reversible variable speed feed means operatively connected therewith to feed the electrode comprising, control means operable to selectively increase or decrease the speed of the feed means from a predetermined value, regulating means responsive to current and voltage conditions of the electrode circuit for controlling the control means to vary speed of the feed means to vary the rate of electrode feed from a predetermined normal value in one direction in accordance with are conditions, and current responsive means operable when the current in the electrode circuit exceeds a predetermined value to effect the feed of the electrode in the reverse direction at an increased speed.

8. An electrode system comprising, a movable electrode for producing an electric arc, reversible variable speed actuating means operatively connected to feed the electrode, speed control means for varyingthe speed of the actuating means to vary the rate of electrode feed in one direction, regulating means responsive to current and voltage conditions of the arc controlling the speed control means, switch means for controlling the speed control means, additional switch means for selectively placing the speed control means under the control of the regulating means or the switch means, and means responsive to predetermined arc current conditions for controlling the actuating means to reverse the direction of electrode feed and render the regulating means inoperative.

CYRIL C. LEVY. 

